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Chapter 1 Tune-up and routine maintenance

leakage. Make sure that all hoses and lines are clear of sharp edges, moving parts and the exhaust system. If any of the above conditions are noted, repair, reroute or replace the lines and/or fittings as necessary (see Chapter 9).

Brake booster check

16.7a With the wheel off, check the thickness of the inner pad through the inspection hole (front disc shown, rear disc caliper similar) with the body or suspension parts, secure the exhaust system with new brackets and hangers.

16.7b The outer pad is more easily checked at the edge of the caliper illustrations). If the lining material is less than the thickness listed in this Chapters Specifications, replace the pads. Note: Keep in mind that the lining material is riveted or bonded to a metal backing plate and the metal portion is not included in this measurement. 8 If it is difficult to determine the exact thickness of the remaining pad material by the above method, or if you are at all concerned about the condition of the pads, remove the caliper(s), then remove the pads from the calipers for further inspection (see Chapter 9). 9 Once the pads are removed from the calipers, clean them with brake cleaner and re-measure them with a ruler or a vernier caliper (see illustration). 10 Measure the disc thickness with a micrometer to make sure that it still has service life remaining. If any disc is thinner than the specified minimum thickness, replace it (see Chapter 9). Even if the disc has service life remaining, check its condition. Look for scoring, gouging and burned spots. If these conditions exist, remove the disc and have it resurfaced (see Chapter 9). 11 Before installing the wheels, check all brake lines and hoses for damage, wear, deformation, cracks, corrosion, leakage, bends and twists, particularly in the vicinity of the rubber hoses at the calipers. Check the clamps for tightness and the connections for

12 Sit in the drivers seat and perform the following sequence of tests. 13 With the brake fully depressed, start the engine - the pedal should move down a little when the engine starts. 14 With the engine running, depress the brake pedal several times - the travel distance should not change. 15 Depress the brake, stop the engine and hold the pedal in for about 30 seconds - the pedal should neither sink nor rise. 16 Restart the engine, run it for about a minute and turn it off. Then firmly depress the brake several times - the pedal travel should decrease with each application. 17 If your brakes do not operate as described, the brake booster has failed. Refer to Chapter 9 for the replacement procedure.

16 Brake system check (every 15,000 miles or 12 months)

Warning: The dust created by the brake system is harmful to your health. Never blow it out with compressed air and dont inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use brake system cleaner only! Note: For detailed photographs of the brake system, refer to Chapter 9. 1 In addition to the specified intervals, the brakes should be inspected every time the wheels are removed or whenever a defect is suspected. 2 Any of the following symptoms could indicate a potential brake system defect: The vehicle pulls to one side when the brake pedal is depressed; the brakes make squealing or dragging noises when applied; brake pedal travel is excessive; the pedal pulsates; or brake fluid leaks, usually onto the inside of the tire or wheel. 3 Loosen the wheel lug nuts. 4 Raise the vehicle and place it securely on jackstands. 5 Remove the wheels (see Jacking and towing at the front of this book, or your owners manual, if necessary).

Parking brake

18 One method of checking the parking brake is to park the vehicle on a steep hill with the parking brake set and the transmission in Neutral (be sure to stay in the vehicle for this check!). If the parking brake cannot prevent the vehicle from rolling, its in need of adjustment (see Chapter 9).

17 Drivebelt check and replacement (every 15,000 miles or 12 months)/tensioner replacement

Drivebelt

1 The drivebelt is located at the front of the engine and plays an important role in the overall operation of the vehicle and its components. Due to its function and material make-up, the drivebelt is prone to failure after a period of time and should be inspected and adjusted periodically to prevent major engine damage.

Disc brakes
Refer to illustrations 16.7a, 16.7b and 16.9 6 There are two pads (an outer and an inner) in each caliper. The pads are visible with the wheels removed. 7 Check the pad thickness by looking at each end of the caliper and through the inspection window in the caliper body (see

16.9 If a more precise measurement of pad thickness is necessary, remove the pads and measure the remaining friction material

Chapter 1 Tune-up and routine maintenance

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17.5 Belt wear indicator marks are located on the tensioner body - when the belt reaches the maximum wear mark it must be replaced A B 17.4 Here are some of the more common problems associated with drivebelts (check the belts very carefully to prevent an untimely breakdown) 2 The vehicles covered by this manual are equipped with a single self-adjusting serpentine drivebelt, which is used to drive all of the accessory components such as the alternator, power steering pump, water pump and air conditioning compressor. tion 1). Rotate the tensioner to relieve the tension on the belt (see illustration). Some models have a square hole in the tensioner arm that will accept a breaker bar or ratchet. On other models, place a wrench on the tensioner pulley bolt. 7 Remove the belt from the auxiliary components and carefully release the tensioner. 8 Route the new belt over the various pulleys, again rotating the tensioner to allow the belt to be installed, then release the belt tensioner. Make sure the belt fits properly into the pulley grooves - it must be completely engaged. Note: Most models have a drivebelt routing decal on the upper radiator panel to help during drivebelt installation. 9 Reconnect the battery. C Stationary mark When the belt is new, this mark will be  near the stationary mark When this mark reaches the stationary  mark, the belt is worn out

Tensioner replacement
Refer to illustration 17.11 10 Remove the drivebelt. 11 Remove the bolt that secures the drivebelt to the engine, then remove the tensioner (see illustration). 12 If youre working on a 5.7L (Hemi) engine, separate the tensioner from the mounting bracket. 13 Installation is the reverse of removal. If youre working on a 3.7L V6 or a 4.7L V8 engine, align the slot on the back of the tensioner with the bolt head on the timing chain cover. Tighten the mounting bolt to the torque listed in this Chapters Specifications.

Inspection
Refer to illustrations 17.4 and 17.5 3 With the engine off, open the hood and locate the drivebelt at the front of the engine. Using your fingers (and a flashlight, if necessary), move along the belts checking for cracks and separation of the belt plies. Also check for fraying and glazing, which gives the belt a shiny appearance. Both sides of each belt should be inspected, which means you will have to twist the belt to check the underside. 4 Check the ribs on the underside of the belt. They should all be the same depth, with none of the surface uneven (see illustration). 5 The tension of the belt is automatically adjusted by the belt tensioner and does not require any adjustments. Drivebelt wear can be checked visually by inspecting the wear indicator marks located on the side of the tensioner body. Locate the belt tensioner at the front of the engine, then find the tensioner operating marks (see illustration). If the indicator mark is outside the operating range, the belt should be replaced.

Replacement
Refer to illustration 17.6 6 Disconnect the cable from the negative terminal of the battery (see Chapter 5, Sec17.6 Rotate the tensioner arm to relieve belt tension 17.11 Drivebelt tensioner retaining bolt (3.7L V6 shown)